Method of forming a decorative image on fabric materials

ABSTRACT

A method of forming a raised image of preselected pattern onto the surface of a fabric material by first laminating a thin film of vinyl onto the surface of the fabric and underlying the fabric with a thin layer of vinyl. A heated die of the image to be formed is then caused to be impressed in a highly forced engagement against the laminated film, while RF energy is applied to the die platen for a controlled time period. The die and image are permitted to cool in place after which the die is removed and any extraneous vinyl particles permeated during the heated engagement can be easily brushed from the fabric surface while the image pattern remains.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a method of embossing a raised image ofselected design onto fabric materials and the product formed by themethod.

2. Description of the Prior Art

Vinyl materials used for upholstering and covering various items, suchas handbags, purses, and attache cases, are commonly produced with aselected decorative image pattern on the surface. Forming the imagepattern typically depends on the use of vinyl layers, separated by abatting composition and against which a heated image die can be imposedunder pressure. Exemplifying this method is the disclosures of U.S. Pat.No. 2,734,982, issued Feb. 14, 1956, to Gillespie et al. While thismethod may be somewhat effective, the fabric product resulting from thismethod has thus far been limited to vinyl.

SUMMARY OF THE INVENTION

This invention relates to the forming of decorative raised imagespatterns on the surface of a variety of different fabric materials. Morespecifically, the invention relates to the method of forming embossedimages on a variety of different fabrics and the products formed by thismethod.

The method of the invention involves: arranging a three layercomposition comprised of a selected sheet of any suitable fabricmaterial, such as polyester; laminating a thin vinyl film onto thefabric surface on which an image is to be formed; and backing the fabricwith an underlying layer of expanded vinyl. After placing thecomposition as a unit in a support tray containing a bed of vulcanizedfiber buffer material, a heated die of image configuration is impressedand maintained against the top surface of the composition for acontrolled time period during which the laminated film is dissipated. Onpermitting the die to cool, the composition is removed, exposing theembossed image raised on the fabric surface.

The above, as well as additional objects features and advantages of theinvention will become apparent in the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a raised image pattern formed on a fabric inaccordance with the invention.

FIG. 2 is sectional view through the composition of materials on whichthe image of FIG. 1 is to be formed.

FIG. 3 illustrates the image forming step by which the raised imagepattern of FIG. 1 is produced.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the drawings, FIG. 2 illustrates an initially preparedthree layer composition 10 and comprising a selected layer of fabric 12on which a thin overlayer film of vinyl 14 has been laminated.Underlying the fabric unattached thereto is a layer of expanded vinyl16. Essential in this relationship, as will be understood, is thatfabric 12, onto which an image 18 is to be formed, comprises acomposition to which a thin thermoplastic film 14 can be laminated.

Exemplifying fabric material 12 suitable for the above is 70 Deniernylon, 400 Denier nylon, 600 Denier polyester, and 1000 Denier cordura.Film 14 will typically be a vinyl film of at least 0.008 inchesthickness, while underlayer 16 will typically be of an expanded vinylcomposition of at least about 0.070 inches thickness.

To form an image 18, a die (not shown) is prepared as by engravingtechniques, corresponding to the image 18. The die is then mounted ontoa heatable platen (not shown) of an RF (radio frequency) or dielectricheat sealer 24 as manufactured, for example, by Hall DielectricMachinery Co., Inc. of Deer Park, N.Y., as their model Series FS.

Positioned beneath a platen press of apparatus 24 is an aluminum tray 20containing a thin layer of electrical grade vulcanized fiber 22, onwhich composition 10 is first placed, as illustrated in FIG. 3. Theplaten is preheated to about 150° F., and then the apparatus 24 isoperated to cause its press to descend, as represented by arrow 26,until engaging its die against composition 10. Typically, the press willapply about a three ton force against composition 10.

With the die engaging the composition 10, the apparatus 24 is caused toeffect a pre-seal for about 1 second, followed by an RF energizing forabout three seconds. At that point, RF energy is removed from theplaten, permitting a cooling cycle for about three seconds with the diestill engaged. The press of apparatus 24 is then retracted, and thecompleted image 18 contained on fabric 12 is exposed. After imagehardening occurs, there remains an embossed image 18, raised from thesurface of fabric 12 and from which the originally laminated film 14 hasbeen dissipated. What is seen by the naked eye is therefore an imagebearing texture of pure fabric 12, part of which contains image 18.

During the sealing cycle, the vinyl film 14 and underlying vinyl layer16 may stick together tending to pull the polyester fabric 12. This cancause an oozing or permeation of the vinyl molecules in transformingfrom a solid to a liquid and back to a solid during the cooling cycle.Any vinyl balls that may have permeated through the surface of thefabric by such oozing are then promptly removed by brushing.

The method of the invention is a novel method of forming embossed imageson a variety of different fabrics and fabric products resulting from themethod. By utilizing a novel composition of materials, carefullyprocessed in a programed sequence, any selected image pattern can bereadily reproduced onto a variety of different fabric materials. Oncethe fabric is thus formed, it can be utilized in a variety of differentapplications such as automobile upholstering, handbags, purses, andattache cases.

Since many changes could be made in the above construction and manyapparently widely different embodiments of this invention could be madewithout departing from the scope thereof, it is intended that all mattercontained in the drawings and specification shall be interpreted asillustrative and not in a limiting sense.

I claim:
 1. A method of forming a raised image of a preselected patternonto a fabric surface, comprising the steps of:selecting a fabric ontowhich an image is to be formed; laminating a thin film of selectedthermoplastic composition unto an upper surface of the fabric on whichthe image is to be formed; placing a layer of selected thermoplasticcomposition underlying said fabric; engaging a heated die of said imagepattern impressed against the laminated film on said fabric; maintainingthe engagement between said die and said laminated film for a controlledtime period sufficient to dissipate said laminated film and expose thefabric thereat; and permitting said die to cool before removing the diefrom said engagement.
 2. A method in accordance with claim 1 in whichboth said film and said underlying layer are comprised of a vinylcomposition.
 3. A method in accordance with claim 2 in which said die ismounted on a heatable platen, said engaging step is preceded by the stepof preheating said platen and there is included the step of applying RFenergy to said platen for said controlled time period to effect saidimage formation.
 4. A method in accordance with claim 3 in which duringsaid engaging step said underlying layer is supported on a buffercomposition.
 5. A method in accordance with claim 4 in which said buffercomposition comprises an electrical grade of vulcanized fiber.
 6. Aproduct formed by the method of claim
 2. 7. A method in accordance withclaim 1 in which said fabric is selected from the group consisting ofnylon, polyester, or cordura.
 8. A method in accordance with claim 1 inwhich said engaging step includes an application of a compression forceagainst said film exceeding at least about two tons.
 9. A method inaccordance with claim 1 including an added step after said cooling stepof removing any undesirable thermoplastic particles permeated onto theimage surface of the fabric during said engaging step.
 10. A productformed by the method of claim 1.